KR102429130B1 - Method for manufacturing bonded sheet using recycling leather for automobile interior material - Google Patents

Abstract

A backing cloth layer for artificial leather, a polyolefin foam layer formed on the backing cloth layer, a polyolefin sheet layer formed on the foam layer, an ink transfer film layer formed on the polyolefin sheet layer, and a thermoplastic polyurethane transparent protective layer formed on the ink transfer film layer An artificial leather having an ink transfer pattern comprising a, and a manufacturing method thereof are disclosed. The artificial leather may include various ink transfer patterns while being based on a polyolefin resin, and may exhibit low ink brittleness, high laminating force and high scratch resistance.

Description

Manufacturing method of cemented sheet for automobile interior material using recycled leather

The present invention relates to a method for manufacturing a cemented sheet material for automobiles having excellent strength and flexibility using regenerated leather technology.

Shaving scrap, a raw material of regenerated leather, refers to leather processing waste or by-products generated by shaving for thickness control after the tanning process, one of the leather processing processes. get angry

The international original patented technology of regenerated leather is owned by Salamanda (Germany) and Japan, and each recipe is different, so the quality of the product is also different.

Regenerated leather sheets are divided into L/B and Composition Leather. In the former case, leather waste is mixed with binder to form a sheet. Depending on the use, urethane and paper powder fiber waste are also combined. It is mainly used as a reinforcement for shoes, a reinforcement for handbags, and a reinforcement for the cover of albums and Bibles.

Compoisition Leather, also called Bonded leather, is a material that has a leather-like surface on L/B. It has a leather-like surface and high tensile strength. There are small items such as stationery and cell phone cases.

The price of regenerated leather is about $23/M for L/B, and the added value is Composition Leather made by Salamanda, which is sold as raw materials for various items and prices such as car seats, bus seats, and airplane seats outside of Mercedes-Benz. It is expected that the use will become more diversified along with fermentation.

Automobile seat fabrics are a major consumer of automobile makers, so they need to respond promptly in line with the basic production and development directions of the automobile makers. Car seat sewing is a business that sews and processes leather and fabric fabrics and sells them to seat companies or automobile companies. It is a project that can promote large-scale employment and develop together with the materials industry such as fabric and leather companies.

On the other hand, since artificial leather is a cutting-edge material and a high-quality material, it responds sensitively to consumer psychology according to the general economy. The interior sector has relatively little impact. There are only two Japanese companies that produce high-quality artificial leather in the world.

Although many studies on the recycling of leather waste are being conducted at home and abroad, the actual utilization rate is very low at less than 10% in Korea. is thought to cause As such, it is expected that development will be made in the direction of minimizing the generation of harmful substances in the manufacturing process due to the strengthening of regulations on the discharge of harmful substances to the human body and the environment. do.

In addition, in terms of commercialization, domestic and foreign related industries are making efforts in various fields by promoting differentiation and high added value in order to break away from producing only simple functional products. The automobile sector is also having a significant impact on related industries that provide interior materials, and is focusing on new countermeasures and technological research such as materials, construction methods, procurement methods, and prices.

In particular, the large amount of fiber used in automobile interior materials is concentrated in the design area that requires superiority of the material's tactile feel, three-dimensional effect, and high-quality feel, and it tends to expand to areas that have not been used before.

As such, automotive interior materials require not only the basic performance of interior materials, but also high design (color and pattern), durable quality such as light resistance and abrasion resistance, selection of materials with low environmental load, and enhanced quality functions such as prevention of contamination and dirt.

The waste generated during the leather process is more than 60,000 tons per year, and the chromium component generated during the leather trimming process is absorbed into the waste and discharged as it is. There is a problem in that various toxic components are released.

Accordingly, the development of recycling and recycling materials using leather waste has been actively carried out in Korea since the late 1990s, but the development of quality enough to be used as a reinforcing material inside a handbag has not been made.

Accordingly, with the development of leather sheets using leather waste that can replace PVC materials while being suitable for car seats, it is necessary to further develop materials with characteristics of high soft, thin thickness, and high tear strength/tensile strength suitable for car seat product characteristics. .

As described above, one of the recent emerging automotive material-related trends is that leather is preferred as an interior material, the difficulty in supplying and supplying raw materials for automobile seats and preference for differentiated materials are increasing, and the low-carbon LCA (Life Cycle) of the automobile industry is increasing. Assessment)-based materials are increasing, and the development of new materials that combine the advantages of natural leather and synthetic leather is required.

Korean Patent Publication No. 10-2013-0131397 (published on December 3, 2013) Korean Patent Registration 10-0828824 (Registered on May 02, 2008)

The present invention was created to solve the above-described problems, and an object of the present invention is to provide a method for manufacturing a cemented sheet material for automobiles that is environmentally friendly, and has excellent strength and flexibility by using regenerated leather technology.

The inventors of the present invention have completed the present invention through the introduction and experiments of various ideas for increasing the mutual bonding properties of leather waste and fiber waste, and for bonding sheet processing conditions and resin processing conditions by a dry method.

As a technical means for achieving the above-described technical problem, a method for manufacturing a cemented sheet for an automobile interior according to an aspect of the present invention includes the steps of preparing a shaving scrap; Putting the saving scrap into a kneader machine (kneader m/c) to obtain a fiber by pulverizing and batting; and mixing the fiber, the main adhesive resin and the auxiliary resin, heating the mixture, and performing roll milling to obtain a sheet.

Here, the saving scrap may have a moisture content of 8 to 15%.

The fiber may be a fiber having a size of 0.4 to 1.0 mm.

The main adhesive resin and the auxiliary resin may be an EVA (ethylene vinyl acetate)-based resin.

The saving scrap may be a mixture of natural leather saving scrap and waste cotton fiber or waste paper.

In addition, the manufacturing method may further include the step of dyeing the obtained sheet after obtaining the sheet.

The manufacturing method may further include the step of adding at least one adjuvant selected from a viscosity enhancing aid, a releasing agent, and a softening agent.

The bonded sheet manufactured according to the present invention is environmentally friendly, and has excellent strength and flexibility, so it can be suitably used for interior materials for automobiles.

The manufacturing method according to the present invention is a product by a dry method rather than a wet method using water, so that it is easy to control the physical properties and thickness of the product, and various product groups can be conveniently manufactured.

According to the present invention, in general, a separate physical process is required for the grinding process to enhance the smoothness and bonding strength of the sheet. It can be combined with and can improve productivity.

In addition, by utilizing leather waste, it is possible to obtain the effect of resource saving and waste reduction through the promotion of recycling of waste, and it is possible to diversify the automotive seat raw material market represented by natural leather and synthetic leather.

1 is a working photograph of a kneader machine according to an embodiment of the present invention.
Figure 2 is a contrast photograph before and after the operation of the kneader machine according to an embodiment of the present invention.
3 is a comparison photograph of test results according to the moisture content of saving scraps according to an embodiment of the present invention.
Figure 4 is a kneader machine processing time and temperature test result data according to an embodiment of the present invention.
5 is a roll mill test result data according to an embodiment of the present invention.
6 is a result data of a waste fiber mixing experiment according to an embodiment of the present invention.
7 is a result data of a lung tumor mixing experiment according to an embodiment of the present invention.

Hereinafter, the present invention will be described in more detail with reference to the accompanying drawings.

The inventors of the present invention have completed the present invention through the introduction and experiments of various ideas for increasing the mutual bonding properties of leather waste and fiber waste, and for bonding sheet processing conditions and resin processing conditions by a dry method.

As a technical means for achieving the above-described technical problem, a method for manufacturing a cemented sheet for an automobile interior according to an aspect of the present invention includes the steps of preparing a shaving scrap; Putting the saving scrap into a kneader machine (kneader m/c) to obtain a fiber by pulverizing and batting; and mixing the fiber, the main adhesive resin and the auxiliary resin, heating the mixture, and performing roll milling to obtain a sheet.

Here, the saving scrap may have a moisture content of 8 to 15%.

The fiber may be a fiber having a size of 0.4 to 1.0 mm.

The main adhesive resin and the auxiliary resin may be an EVA (ethylene vinyl acetate)-based resin.

The saving scrap may be a mixture of natural leather saving scrap and waste cotton fiber or waste paper.

In addition, the manufacturing method may further include the step of dyeing the obtained sheet after obtaining the sheet.

The manufacturing method may further include the step of adding at least one adjuvant selected from a viscosity enhancing aid, a releasing agent, and a softening agent.

On the other hand, when a certain part "includes" a certain component throughout the present specification, this means that other components may be further included, rather than excluding other components, unless otherwise stated. Also, when a part is said to be located "above" another part, it can include not only the case where it is located above in direct contact with it, but also the case where it is positioned above another component in the middle. have.

Hereinafter, embodiments of the present invention will be described in detail so that those of ordinary skill in the art can easily carry out the present invention. However, the present invention may be embodied in several different forms and is not limited to the embodiments described herein.

Differentiation test

As the devices used for the physical treatment experiment in this experiment, a dry grinding device such as a disk mill, a cutting mill, a Kneader m/c, and a wet grinding device, a Niagara beater, were used.

As a result of fiber pulverization using a cutting mil, disk mill, kneader m/c, and Niagara beater, it was confirmed that the average fiber length was 0.4~1.0mm during the grinding process using the kneader m/c, making the fibers the most short. . When the length of the fiber is less than a certain size, the formability is poor due to deterioration of physical properties and poor bendability, and the length of the fiber is excessively long and the surface touch property is very poor. The fiber length of about mm showed the best inter-fiber bonding strength and surface properties.

treatment method cutting mill disk mill Kneader m/c Niagara beater Average fiber length (mm) 2.0~3.0 1.0~2.0 0.4~1.0 3.0~4.0

As a result of putting the shaving scrap into the Kneader m/c without pulverizing and cutting the shaving scrap, as shown in FIG. 2 above, the effect of pulverization and rubbing occurred, and a separate pulverization process was unnecessary.

Characteristic test according to processing time and temperature of Kneader m/c

EVA resin is insoluble and affects adhesion in the presence of water.

It is necessary to determine the appropriate moisture content suitable for sheet manufacturing through moisture content measurement

The shaving scrap collected at the site and the shaving scrap left naturally for 7 days have a moisture content of 30 to 55% and 16%. There is a problem with the performance (this is the result of moisture interfering with the bonding of the resin and S.C)

The amount of shaving scrap used was reduced from 20 g to 10 g, and the experiment was conducted. As a result of the E-1 and E-1-1 experiments, as in E-1-1, when the shaving scrap content was 20 g and resin 8 g, the bonding strength between fibers Due to this decrease, the adhesion strength during roll milling was very insufficient, so E-1-1 formulation was not suitable. Good adhesion, good roll mill workability.

While the content of the resin compared to the shaving scrap was kept constant at 80%, the mixing time of the kneader m/c was changed to 5 minutes, 10 minutes, and 15 minutes to produce a sheet. As a result, the resin and the shaving scrap were uniformly mixed. In the case of short A-1, A'-1, which is the kneader m/c mixing time, the thickness of the final sheet is many and non-uniform. However, when the kneader m/c mixing time is given for 15 minutes, the appropriate sheet It shows the characteristics that can manufacture a sheet with a uniform thickness.

The problem of poor adhesion between fibers due to the addition of moisture to the insoluble resin was solved by adjusting the moisture content of the shaving scrap to about 10%. cases were resolved, and overall excellent characteristics were exhibited.

Sheet uniformity test according to roller mill pressure and rotation speed

All conditions were the same for B-1 and B'-1, and an experiment was conducted to check the uniformity of the sheet according to the pressure of the roll mill used for manufacturing the sheet of mixed resin through the Kneader m/c operation.

As a result, when the pressure of the roll mill was 50 kgf/cm2 or less, uniform sheet production was not made and a sheet with an uneven surface was manufactured. The mill pressure is more than 100kgf/cm2.

As a result of manufacturing the sheet by changing the rotation speed of the roll mill from 10r.p.m to 20r.p.m, in the case of B''-1 and B'''-1 with high r.p.m, smooth sheet production was not achieved, and the roll mill There was a problem in that it was difficult to separate the sheet, and it was difficult to manufacture a uniform sheet because the contact time between the roll and the sheet was short due to the high rotation speed.

Therefore, the pressure of the roll mill was 100gf/cm2, and the rotation speed of the roll mill was 10r.p.m, which shows the most suitable result in the properties and uniformity of the sheet of B'-1.

Bonded Sheet Resin Processing Condition Test

Pellet resin was applied with a resin having a melting point of 110℃ or less, because the shrinkage temperature of the shaving scrap is 110℃ to manufacture the sheet under the condition that the deformation of the shaving scrap does not occur.

- Resin mixing experiment by fixing with 15g of shaving scrap

- Kneader m/c mixing time: 15 minutes

adhesive resin division characteristic VA 810 VA-1 No auxiliary resin / Hard / Poor flexibility / Poor bending VA-2 Somewhat Hard / Poor flexibility / Normal bending VA-3 Good flexibility/bendability VA-4 Strength/Flexibility Moderate/Bendability Good VA-5 Somewhat Hard/Normal Flexibility/Normal Flexibility VA-6 Normal strength / Normal flexibility / Normal bendability VA-7 Poor meltability of LDPE 5302 and present in foamed form VC 710 VC-1 No auxiliary resin/Hard/Normal flexibility/Good bendability VC-2 Somewhat Hard / Poor flexibility / Normal bending VC-3 Somewhat Hard / Poor flexibility / Normal bending VC-4 Somewhat Hard / Poor flexibility / Normal bending VC-5 Somewhat Hard / Poor flexibility / Normal bending VC-6 Somewhat Hard / Poor flexibility / Normal bending VC-7 Poor meltability of LDPE 5302 and present in foamed form EVA 1633 E1633-1 No auxiliary resin / Hard / Poor flexibility / Poor bending E1633-2 Somewhat hard / poor flexibility / poor bending E1633-3 Hard / Poor flexibility / Normal bending (EVA 1834) E1633-4 Somewhat hard / poor flexibility / poor bending E1633-5 Very hard / poor flexibility / poor bending E1633-6 Very hard / poor flexibility / poor bending E1633-7 Sheet not manufactured due to poor meltability of LDPE 5302 EVA 1540 E1540-1 No auxiliary resin E1540-2 Poor compatibility with auxiliary resin/defective flexibility/defective bending E1540-3 Poor compatibility with auxiliary resin/defective flexibility/defective bending E1540-4 Poor compatibility with auxiliary resin/defective flexibility/defective bending E1540-5 The sheet could not be manufactured due to poor compatibility with auxiliary resin. (MB-100) E1540-6 Sheet cannot be manufactured due to poor compatibility with auxiliary resin. (E-220F) E1540-7 Sheet not manufactured due to poor meltability of LDPE 5302

When VA 810 is applied, VA-1 treated with VA 810 alone has a problem in that bending properties and flexibility are somewhat inferior, but in the case of VA-3, 4, 5, and 6 with 10% auxiliary resin applied, bending properties and flexibility are poor. Relatively good result. (Compatibility between VA 810 and auxiliary resin EVA 1834/VS 430/MB-100/E 220F)

When VC 710 was applied, overall somewhat hard characteristics (in the case of using VC 710 and auxiliary resin, there was little change according to the characteristics of auxiliary resin, and mainly due to the influence of VC 710, which is the main adhesive resin, hard characteristics)

EVA 1633 resin is used for hard applications and has excellent optical adhesion, so overall strength is strong and flexibility is poor.

EVA 1540 is the material with the best flexibility, strength, and bendability when the resin content is 30-40% in the previous experiment, but it has no compatibility with adjuvants, making it difficult to manufacture sheets, Flexibility, bendability, etc. are very poor problems exposed.

VA 810 is used as the main adhesive resin, and EVA 1834 auxiliary resin is suitable.

Experiments by moisture content of shaving scrap applied with main adhesive resin and auxiliary resin

The standard content of the experiment was 40 g of shaving scrap (moisture content: 10%), 32 g of VA 810 (80% of S.C) and 8 g of EVA 1834 (20% of S.C).

If the moisture content is more than 10%, the moisture inside does not escape due to the addition of the resin, so the fiber bonding strength is poor.

Fiber mixing experiment

Looking at the physical property analysis table above, in the case of using 10% of waste cotton fiber and 10% of waste paper in the total fiber content, the overall physical properties showed the best results, and even if the amount of waste cotton fiber and waste paper was continuously increased, Since there is no significant effect on physical properties, it is judged that it is appropriate to fix the amount used at 10% in terms of physical properties.

In the case of using VA 810 + EVA 1834, the VA content was slightly lower at 33%, so the tacky problem on the surface was significantly reduced.

The adhesive resin used must have a VA content of 30% or more to form adhesion between fibers, and a resin with a melting point of 80°C or lower (processing temperature Max 110°C) is suitable. lim.

However, in the case of using VA 810 + EVA 1834 in overall physical properties, it has excellent physical properties that are not too difficult for product manufacturing, and also has excellent productivity characteristics due to reduced tackiness, confirming that it is possible to use an appropriate resin depending on the use of the product. .

Evaluation items danwin SC-1 SC-2 SC-3 SP-1 SP-2 SP-3 thickness mm 0.8 0.8 0.9 0.8 0.9 0.8 The tensile strength kgf/1.27m 3.7 3.6 3.3 3.9 3.5 3.2 tear strength kgf 0.3 0.4 0.5 0.4 0.4 0.6 elongation % 12.4 11.3 11.7 13.7 16.7 11.3 flexibility mm 3.0 3.0 3.0 2.8 3.3 2.6

Optimal manufacturing process

When testing by WS 180 usage, the optimal usage of WS 180 is 15% to 20% of the resin content.

division Shaving scrap (S.C) VA 810 EVA 1834 WS 180 Tacky flexibility VAS-6-2 40g 32g 8g 6 g (15% of resin) 2-3 Hard VAS-6-3 40g 32g 8g 7 g (17.5% of resin) 1-2 Hard VAS-6-4 40g 32g 8g 8 g (20% of resin) 1-2 Hard

When testing by ST/A usage, the optimal usage of ST/A is 2.5~20% of the resin content.

division Shaving scrap (S.C) VA 810 EVA 1834 ST/A Tacky flexibility VAW-1-1 40g 32g 8g 1 g (2.5% of resin) 2-3 Medium VAW-1-2 40g 32g 8g 2 g (5% of resin) 2 Medium VAW-1-3 40g 32g 8g 3 g (7.5% of resin) 2-3 Medium VAW-1-4 40g 32g 8g 4 g (10% of resin) 2-3 Medium VAW-1-5 40g 32g 8g 5 g (12.5% of resin) 2-3 Medium VAW-1-6 40g 32g 8g 6 g (15% of resin) 2-3 Medium VAW-1-7 40g 32g 8g 7g (17.5% of resin) 2-3 Medium VAW-1-8 40g 32g 8g 8 g (20% of resin) 2 Medium

Optimization result with no lubricant added

division content Shaving scrap (S.C) (moisture content: 10%) 40g VA 810 (80% of fiber) 32g EVA 1834 (20% of fiber) 8g

W-1500 : Increases the flexibility and viscosity of the paste, but the roll mill adhesion problem and physical properties decrease

ST/A and WS 180 produce tacky improvement effect when used compared to the above content

Physical properties: Blank (no lubricant) > ST/A mixed > WS 180 mixed

Manufacturing process

Shaving scrap Moisture content: 10%

Kneader m/c Setting temp. : 95℃ (high melting temperature of applied resin)

Kneader m/c Mixing time: Fiber alone: 5 minutes (pulverization) -> Resin mixing: 10 minutes (adhesion)

Roll mill rotation speed: 10r.p.m

Roll mill pressure: 100kgf/cm2

1st Roll mill temp. : 90℃ / 2nd Roll mill temp : 50 or 85℃

The description of the present invention as described above is for illustration, and those of ordinary skill in the art to which the present invention pertains will understand that it can be easily modified into other specific forms without changing the technical spirit or essential features of the present invention. will be able Therefore, it should be understood that the embodiments described above are illustrative in all respects and not restrictive. For example, each component described as a single type may be implemented in a dispersed form, and likewise components described as distributed may also be implemented in a combined form.

The scope of the present invention is indicated by the following claims rather than the above detailed description, and all changes or modifications derived from the meaning and scope of the claims and their equivalents should be interpreted as being included in the scope of the present invention. do.

Claims (7)

Preparing a shaving scrap (shaving scrap);
Putting the saving scrap into a kneader machine (kneader m/c) to obtain fibers by pulverizing and batting; and
Mixing the fibers, different types of main adhesive resin and auxiliary resin, heating, and roll milling to obtain a sheet
including,
The saving scrap has a moisture content of 8 to 15%,
The fiber is a fiber having a size of 0.4 to 1.0 mm. delete delete The method of claim 1,
The main adhesive resin and the auxiliary resin is an EVA (ethylene vinyl acetate)-based resin, a method of manufacturing a cemented sheet for an automobile interior material. The method of claim 1,
The saving scrap is a method of manufacturing a cemented sheet for automobile interior materials, which is a mixture of waste cotton fibers or waste paper with natural leather saving scraps. The method of claim 1,
Method of manufacturing a cemented sheet for automobile interior material further comprising the step of dyeing the obtained cemented sheet. The method of claim 1,
A method of manufacturing a cemented sheet for automobile interior material further comprising the step of adding at least one auxiliary agent selected from a viscosity improving agent, a release agent, and a softening agent.

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